Building a Home Gym on a Budget: Roman Strength's Journey from Army Musician to Fitness Entrepreneur
Creating an impressive home gym doesn't have to break the bank. This is one of the key takeaways from Rory Ellis's journey building both his personal training space and his fitness equipment company, Roman Strength.
Affordable Home Gym Construction
Contrary to popular belief that building a dedicated home gym structure costs $30,000-$50,000, Rory shares that his build came in around $15,000 with help from a friend. The key was shopping around for the structure itself and being strategic about his equipment purchases.
“A lot of people think like, ‘oh, there must have been like 30, 40 grand.' It's like, dude, no way. Just no way I could afford that,” Rory explains.
His initial setup included a Rep Fitness PR-5000 power rack as his foundation piece, with most subsequent additions coming from marketplace finds at significant discounts.
The Birth of Megalith Handles
What really sets Rory's story apart is how his experience in his home gym led to product innovation. As a former physical therapist, he found using standard jammer arms uncomfortable on his shoulders and elbows.
“I was using the jammer arms for a lot of things because I was doing my squat, bench, deadlift, and then I wanted accessories,” Rory explains. “But I found it frustrating, especially with my background in physical therapy – the angles on my elbows and shoulders was just really uncomfortable.”
After seeing a commercial gym attachment that inspired him, Rory envisioned a solution. Using parts from Amazon and a $75 Harbor Freight welder (with no previous welding experience), he created the first prototype of what would become the Megalith handles – articulating handles that dramatically improve jammer arm functionality.
From Prototype to Product
With help from Britain of Vendetta Fitness, who assisted with CAD drawings and manufacturing refinements, Rory transformed his rough prototype into a market-ready product. The Megalith handles have become his flagship product, with several variations and accessories now available.
“Britain was able to take the initial idea and just make it more applicable to manufacturing,” Rory notes. “He really made it so it just takes up the one hole spacing, which is amazing.”
The product line has expanded to include:
- The original Megalith handles
- NERLDNUT attachments
- Neutral grip handles (coming soon)
- Dual-sided weight horns
- Various additional accessories for versatility
Business Growth and Challenges
Roman Strength has grown more quickly than Rory anticipated, but he maintains realistic expectations about its sustainability. Currently still working his Army job, Rory reinvests all profits back into the business.
“The goal with Roman Strength… has always been just to be able to replace my wife's income,” he shares. “And she's a teacher. So it's not a huge income to replace. And it's looking like maybe potentially next year that could happen.”
This would allow his wife to homeschool their daughters, aligning with their family values.
Rory has navigated patent considerations (opting for a design patent rather than a more expensive utility patent) and manufacturing challenges. Initially trying to manufacture in Tennessee, quality control issues and cost led him to overseas production for the main components, while sourcing hardware domestically.
Looking Ahead: Home Gym Con
Rory is preparing to exhibit at Home Gym Con, where he'll share booth space with Vendetta Fitness while also competing in the strongman throwdown. He'll be bringing his full product line, including prototypes of upcoming releases.
For home gym enthusiasts looking to follow in Rory's footsteps, his journey offers several valuable lessons:
- Start with quality foundational equipment
- Look for marketplace deals to expand
- Think creatively about solving your own training challenges
- Don't be afraid to start small when developing products
Rory's story demonstrates that with patience, creativity, and strategic investment, both a great home gym and a successful fitness equipment business are within reach.
